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Prompted by surging power demand from oil and gas facilities, power generation is becoming an increasingly significant and challenging topic in the industry. Nevertheless, the alpha and omega in the oil and gas business is still energy security. Production, processing and refining of oil and gas is an energy-intensive process, and a secure, reliable and economic source of energy is vital to ensure profitable operations.
Backed by decades of experience with utility-type and industrial power generation, Siemens draws on a wealth of knowledge to deliver dependable, economical and environmentally-friendly solutions for any stage, process and application in the oil and gas industry.
Compact, lightweight turbine package designs
Siemens can provide such energy locally through the use of their broad range of gas turbines and steam turbines. A variety of compact package designs ensure that these units are suitable for any environment for which they may be required, onshore or offshore, desert, jungle or Arctic. Single-lift, modular and transportable designs are also available to allow transportation in more remote regions, reduce installation times and minimize the number of personnel required on site in sensitive environmental areas.
Siemens turbines are available for power generation in the oil and gas industry as pre-tested modularized packages, including: Gas or steam turbine, Generator, Acillary and auxiliary systems, Installation and Project management.
If solely electricity is required, then Siemens can provide gas turbines in open cycle or combined cycle configurations. High availability, extended times between inspections, choice of on-site maintenance or core exchange, and the ability to change out a gas generator in 24 hours, ensure maximum uptime.
With high reliability and availability minimizing plant downtimes, and the ability to operate on a wide variety of fuels, power is available when you require it.
Fuel flexibility is our strength
While traditionally operated on natural gas, Siemens’ gas turbines are able to operate on a wide range of gas or liquid fuels, using either conventional combustion technologies, or the robust Dry Low Emissions (DLE) technologies to ensure minimum environmental impact.
If no natural gas infrastructure is available, the gas turbines could utilize the associated gases from oil production, or on some models even bi-fuel – operate on a mixture of gas and liquid fuels simultaneously if insufficient gas is available to fully fuel the turbine.
SGT-800: High efficiency, high availability
The SGT-800 gas turbine was designed to maximize energy efficiency and minimize downtime in Cogeneration applications. While the SGT-800 can be overhauled on site, the core exchange maintenance concept reduces scheduled downtime to less than 60 days over 17 years. With an electrical power output of 47 or 50.5 MW, the SGT-800 can produce, unfired, in excess of 85 tonnes/hour of dry saturated steam at 66 bara pressure, an overall energy efficiency of over 80%. By firing to 925°C, over 185 tonnes/hour of steam at the same conditions can be produced, a similar volume to that from a 85MW class heavy duty gas turbine, while increasing the overall energy efficiency of the cogeneration plant to over 91%.
SGT-500: Heavy Fuel Oil Capability
For over 50 years this gas turbine has served the oil & gas and power industries, delivering power with outstanding operational reliability both onshore and offshore. The SGT-500 is unique within the Siemens portfolio in its ability to operate on non-premium liquid fuels, including relatively viscous fuels such as heavy fuel oil (HFO), or even potentially treated crude oils as low as 13° API gravity, refinery residual oils and bio-oils.
The burner design is able to accept liquid fuels with viscosities up to 20cSt, more than twice the permissible viscosity of most gas turbines. Combined with the pressurized fuel system that allows the fuel to be pre-heated to as high as 150°C to reduce the fuel viscosity, it is possible to use fuels with viscosities of 750cSt at 50°C or higher in the SGT-500. This allows the operator to use common heavy fuel oils such as IM380, as well as crude oils and residual oils from refining processes. Where it is necessary to comply with strict environmental regulations, water injection can be used to reduce NOX emissions. Depending on the carbon residue value of the fuel, it is possible to achieve NOX emissions below 50 ppm across the whole load range. The SGT-500 also has the ability to bi-fuel – to operate on a mixture of both gas and liquid fuels. This feature reduces the need to flare associated gas, or allows the gas to be used for other process purposes, such as gas lift.
Its low firing temperature contributes to an impressive maintenance program, with an expected 80,000 hours between major overhauls, 10,000 hours of operation between inspections and with a core exchange program, potentially just 24 days downtime in 10 years – that is an availability of more than 97%.
More info: Siemens gas turbines
Alternatively, in the oil and gas downstream business a steam turbine-based solution may be preferred, for which Siemens can supply proven condensing and back-pressure designs, for reliable operation on either superheated or dry saturated steam. Steam extraction is also available for process use. Available for both power generation and mechanical drive applications, Siemens’ steam turbines are designed for maximum uptime, can come in modular packages and are suitable for onshore or offshore installations.
More info: Siemens steam turbines
Offering high reliability and maximum availability, combined with ease of operation and fuel flexibility (including the potential for bi-fuelling – operation on gas and liquid fuel simultaneously), a single power plant based on Siemens gas turbines or steam turbines can provide both the electricity and steam required for the operations reliably and economically. By recovering the waste heat from the gas turbine and processing it through a heat recovery steam generator, steam can be produced for use in heating or other production processes.
Heat recovery increases operational economy
This concept, known as Cogeneration or Combined Heat & Power (CHP), maximizes the energy efficiency of a facility, offering overall fuel efficiencies of over 90%. It provides the electricity needed for the production or refining process and at the same time produces almost all the steam required.
Increasingly, thermal recovery techniques, such as Cyclic Steam Injection (CSS) or Steam Assisted Gravity Drainage (SAGD), are being employed to maximize oil recoveries, e.g., in Heavy Oil production. The waste heat in the exhaust of a gas turbine can be recovered and used to produce the steam required for injection, or to heat other fluids that may be used in the operations. The high proportion of oxygen in the exhaust gases of a gas turbine offer the option to install a duct burner to boost steam production to even higher levels.
Using steam turbines to optimize efficiency
Steam turbines can also be used for Cogeneration plants: by increasing the pressure at which the steam is generated in the boiler plant, a back-pressure steam turbine can be installed generating a large percentage of, and potentially all, the power required for operations, while still allowing steam to be distributed around the oilfield at a sufficiently high pressure to minimize condensate production. Siemens’ range of steam turbines is capable of operating on saturated steam, removing the need for superheaters and expensive boiler plant.
Innovative solutions using steam turbines
At the remote wellpads, Siemens’ mini steam turbines SST-040 can be used in place of pressure reduction valves, reducing steam pressure from distribution pressures down to the pressures required for injection, and generating the power required for pumps and instrumentation, potentially allowing the wellpad to operate independently from the central power plant.
Waste heat from upgrading and refining processes can be used to produce steam for additional power generation, or to drive a steam turbine for pumping or compression duties. Such concepts minimize reliance on external power supplies, making the best use of locally produced heat energy. This way energy costs and CO2 emissions can be reduced.
With all these intercompatible, proven products globally available, Siemens Energy Oil & Gas can provide the optimum energy solution for your oil and gas operations.
TES (Termoelektrarna Sostanj d.o.o) selected Siemens to supply two SGT-800 gensets for block 5 of their Sostanj power plant in central Slovenia. Siemens scope of supply:
Tuesday April 21, 2009 saw the inauguration and official opening of Peru’s first industrial cogeneration power plant in Callao, west of Lima.
Siemens’ scope of supply:
The Würzburg power authority had decided early in 2007 to increase the capacity of their existing combined-cycle plant to improve its economy. Siemens’ scope of supply: